Method and apparatus for texture embossing a sheet of material



April 26, 1966 R. s. sI-IULTZ 3,247,785

METHOD AND APPARATUS FOR TEXTURE EMBOSSING QIIIIHIIHIH|!\`\`\\\\\\\\\\\IIIIHHWW-"% Filed June 19, 1963 2 Sheets-Sheet 1 III III-:Q

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PRIoR ART PRIOR ART I F|G.4 F|G.5

INVENTOR. RICHARD s. sHuLTz BY 4*/ PRIOR ART Zwd/ Z/M HIS ATTORNEYS April 26, 1966 R. s. sHULTz 3,247,735

METHOD AND APPARATU OR TEXTURE EMBOSSING A SHEET MATERIAL Filed June 19, 1963 2 Sheets-Sheet Z 47 4f Q j f F|G.7

Ilm/111' j F I G 8 INVENTOR RICHARD S. SHULTZ HIS ATTORNEYS United States Patent Office 3,247,785 Patented Apr. 26, 1966 3,247,785 METHOD AND APPARATUS FOR TEXTURE EMBOSSING A SHEET OF MATERIAL Richard S. Shultz, Henrico County, Va., assignor to Reynolds Metals Company, Richmond, Va., a corporation of Delaware Filed .lune 19, 1963, Ser. No. 289,077 1l Claims. (Cl. lill-23) This invention relates to an improved `and continuous method and apparatus for texture embossing a sheet of material or the like as well as to improved. parts for such an apparat-us or the like.

It is well known that a textured embossed sheet of material comprises a plurality of different surface areas each Ibeing embossed with straight and parallel lines disposed at an `angle relative to the lines in other areas so that the light will reflect at different angles at the different areas so that the different areas will have different or contrasting appearances.

In this manner, while two areas of the sheet of material may be colored with the same color, the net result is that the two like colored areas will have the appearance of different hues because of the different light reiiecting patterns produced by the line embossing thereof.

Such line embossing is provided by forming a plurality of minute alternating valleys and hills in the surface of the sheet of material whereby there are at least fifty valleys or hills per inch of the sheet of material to produce the above effect.

Such applications of texture embossing are well known in the greeting card field.

However, such prior known texture embossing method is accomplished on sheet fed, low speed flat bed equipment whereby such prior known texture embossing methods and apparatus are inapplicable to forming decorative wraps for containers and the like as the cost of the prior known texture embossing method is prohibitive in this highly competitive eld.

According to the teachings of this invention, however, a continuous method -and apparatus is provided for texture embossing a sheet of material with a repeating pattern whereby the sheet of material can compete with other decorative wraps and have the advantages of texture embossing in a manner hereinafter set forth.

Accordingly, it is an object of this invention to provide a continuous method of texture embossing a sheet of material or the like.

Another object of this invention is to provide anapparatus for continuously texture embossing a sheet of material or the like.

A further object of this invention is to provide improved parts for such an apparatus or the like.

Other objects, uses and advantages of this invention are apparent from a reading of this description which proceeds with reference to the accompanying drawing forming a part thereof and wherein:

FIGURE 1 is a view illustrating the basic function of a textured embossed sheet of material or the like.

FIGURE 2 is a view similar to FIGURE 1 illustrating another feature of texture embossing.

FIGURE 3 is a View similar to FIGURE 2 and illustrates still another feature of texture embossing.

FIGURE 4 is a schematic cross-sectional view illustrating the prior art method and apparatus for texture embossing a sheet of material or the like.

FIGURE 5 is a view similar to FIGURE 4 and illustra-tes the apparatus in one of its operating positions thereof.

FIGURE 6 is a fragmentary cross-sectional view illustrating another prior art method and apparatus.

FIGURE 7 is a schematic side view illustrating the improved method and apparatus of this invention.

FIGURE 8 is an enlarged, fragmentary, cross-sectional view illustrating the embossing roll of the apparatus of FIGURE 7.

FIGURE 9 is a View similar to FIGURE 8 and illustrates the backup roll of the apparatus of FIGURE 7.

FIGURE 10 is an enlarged, fragmentary, cross-sectional view illustrating how the rolls of FIGURES 8 and 9 cooperate together to texture emboss a sheet of material according to the teachings of this invention.

While the various features of this invention are hereinafter described and illustrated Vas being particularly adaptable for texture embossing a sheet of Imaterial to be subsequently utilized as a decorative wrap for a container or the like, it is to be understood that the various features of this invention can be utilized singly or in any combination thereof to provide other .articles as desired.

Therefore, this invention is not to be limited to only the embodiments illustrated in thedrawings, because the drawings are merely utilized to illustrate one of the wide variety of uses of this invention.

Referring now to FIGURE l, a sheet of material 20 has been textured embossed in such a manner that a plurality `of cubes 2l appear on the sheet of material 20, each cube 21 having a side 22 thereof formed by a plurality of straight and substantially parallel hills 23 :and valleys 24 -arranged in alternating relation to give the same a ribbed effect disposed angularly relative to the direction of the hills 23 and valleys 24 of adjacent areas of adjacent cubes 2l.

In this manner, if the face of the sheet of material 20 is formed of the same color throughout the entire area thereof, the cubes 21 will tend to be formed of different hues of that particular color because the various sets of hills 23 and valleys 24 of the different sides of different cubes 2l reflect the light in different :manners so that certain areas of the sheet of material 20 appear to have darker hues than other `areas thereof.

Such an appearance is provided by having at least fifty hills 23 or fifty valleys 24 per inch of the sheet of material Ztl and it is preferable that such hills or valleys be in the order of approximately seventy-live per inch of the sheet of material 20.

Because the hills 23 and valleys 24 are so minute, the number' of lines illustrated in FIGURES 1, 2 and 3 of this invention are ymerely forpurposes of illustration and do not tend to represent fty or more lines per inch.

While the texture embossing pattern illustrated in FIG- URE l` has each set of valleys 24 and hills 23 substantially uniform with the other sets thereof, it is to be understood that such text-ure embossing pattern can be utilized to highlight a picture scene or the like.

In particular, reference is made to FIGURE 2 wherein a sheet of material 25 has the major portion thereof provided with a set of valleys 24 and hills 23 disposed angularly to the horizontal while an irregular area 26 thereof has the hills 23 and valleys 24 disposed atV a different angle relative to the valleys 24 and hills 23 of the major portion of the sheet 25.

In this manner, the irregular embossed area 26 gives the appearance of a cloud in the sky even though the entire sheet of material 25 is colored with the same color, the cloud 26 either having a lighter or darker hue than the surrounding sky depending upon the direction of the light impnged on the sheet of material 25 and on the position of the observer relative to the sheet of material 25.

Similarly, such texture embossing can be utilized to give a rippliug effect to a desired portion of a sheet of material.

For example, reference is made to FIGURE 3 wherein a sheet of material 27 is provided to depict a stream of water that is defined by a plurality of irregular areas 28 each having the hills 23 and valleys 24 thereof disposed at different angles relative to the adjacent areas 28 thereof whereby the overall appearance of the texture embossed pattern illustrated in FIGURE 3 gives the appearance that the water is rippling even though the entire sheet of material 27 is colored with the same color.

Therefore, it can be seen that texture embossing can be utilized to accentuate various elements in a design by angling the valleys and hills of those various elements for direct reflectivity While adjacent elements of the design are angled in other directions for indirect, less brilliant reflection.

Further, such texture embossing can be utilized to make one color serve the function of two or more. Again, this is the result of the angling of the respective embossed valleys and hills.

In addition, such texture embossing can give the appearance of motion through the use of sharply contrasting angles in the manner set forth in FIGURE 3.

Therefore, it can be seen that such texture embossing is readily adaptable to landscape designs. However, it is to be understood that such texture embossing can be advantageously applied to other package designs to accentuate brand names, produce vignettes or other elements as desired.

As previously set forth, the only prior known method of texture embossing was to utilize a discontinuous method and apparatus known as a sheet fed, low speed, flat bed apparatus.

In particular, such prior known apparatus is illustrated in FIGURES 4 and 5 and is generally indicated by the reference numeral 29.

The prior known apparatus 29 comprises a bed plate 30 having a flat surface 31 to receive a sheet of material 32 to be subsequently textured embossed by a texture embossing die 33 having the lower surface 34 thereof provided with a plurality of minute cavities 35 arranged in a desired texture embossing pattern in the manner set forth above.

The apparatus 29 is utilized to texture emboss the sheet of material 32 with the sheet of material 32 comprising layer of metallic foil 36, such as aluminum-containing metallic foil or the like, laminated to a strip of paper backing material 37 by a readily compressible layer of wax-like material 38 for a purpose now to be described.

When the embossing die 33 is moved toward the bed plate 30 with the sheet of material 32 disposed therebetween, the surface 34 of the embossing die 33 forms impression in the sheet of material .32 in the manner illustrated in FIGURE whereby the resulting compressed wax-like layer 38 below the surface 34 ows upwardly to tend to ll the cavities 35 of the embossing die 33 whereby the sheet of material 32 will have the desired valleys and hills formed therein in a desired pattern.

While the prior art method which relies on the flow of wax into the cavities 35 is suitable for embossing single sheets of material, it does not lend itself to the use of high speed web material. This is because of the fact that as the wax is permitted to expand freely into the cavity 35, there is a component of wax flow which is directly opposite to the direction of web feed. This results in a strain on and frequent breakage of the web.

Therefore, in order to provide wraps for containers and the like by the method illustrated in FIGURES 4 and 5, individual sheets of material have to be placed in the apparatus 29 and embossed in the slow process illustrated therein. Thereafter, the embossed sheets of material would have to be shipped and stored in sheet form which further adds to the cost of handling the prior known textured embossed sheets of material.

The above method of texture embossing should not be confused with the well known method of registered embossing wherein mating rolls register emboss a sheet of material to give a three-dimensional effect thereof.

For example, such a register embossing apparatus is generally indicated by the reference numeral 39 in FIG- URE 6 and comprises a pair of cooperating rolls 40 and 4i respectively having cavities 43 formed therein which mesh with the uninterrupted portions of the adjacent roll in the manner illustrated in FIGURE 6 to continuously emboss a sheet of material 44 passing through the nip of the rolls 40 and 41.

Because great precision is required in forming the mating female and male parts of the rolls 40 and 4I to provide the registering embossing on the sheet 44, the cost of forming the rolls 4t) and 41 to provide texture embossing wherein more than 50 hills or valleys are provided per inch of the sheet of material 44 is prohibitive if not impossible.

Therefore, it can be seen that registering embossing as illustrated in FIGURE 6 gives a three-dimensional depth to chosen design elements whereas textured embossing gives little depth effect and only gives dimensional effects and contrast not through the embossed appearance itself, but rather through its effect on light reflectivity.

Therefore, it can be seen that the only prior known methods and apparatus for texture embossing a sheet of material are the slow, sheet-fed apparatus 29 illustrated in FIGURES 4 and 5.

However, according to the teaching of this invention an improved apparatus and method is provided wherein a sheet of material can be continously textured embossed whereby the sheet of material can be stored in roll form for easy shipment and storage thereof and for use in conventional high speed container wrapping machinery.

For example, reference is made to FIGURE 7 wherein the improved method and apparatus of this invention is generally indicated by the reference numeral 45 and comprises an embossing roll 46 and a cooperating backup roll 47 operating in a manner hereinafter described to continuously emboss a sheet of material 4S continuously drawn through the nip of the rotating rolls 46 and 47 from a free wheeling supply roll 49 onto a windup roll 5t) driven at the proper speed.

The rolls 46 and 47 of the apparatus 45 of this invention are so constructed and arranged in a manner hereinafter described that the strip of material 48 can be fed through the nip of rolls 46 and 47 at a relatively fast rate while the rolls 46 and 47 cooperate together to continuously texture emboss the sheet of material 4S with a repeating pattern in a manner to provide the desired effect-s set forth above.

The embossing roll 46 comprises a member 51 which may be steel, aluminum or other metal provided that it has sufficient rigidity having the outer periphery thereof plated with an etchable material 52, such as copper or the like.

In this manner, the outer peripheral surface 53 of the etchable layer 52 can be etched with the desired texture embossing pattern to produce the valleys and hills previously set forth by conventional photoengraving etching processes or the like whereby the outer peripheral surface 53 of the etchable layer 52 of the embossing roll 46 is provided with a plurality of cavities 54 which will subsequently form the hills in the sheet of material 48 in a manner hereinafter described.

The backup roll 47 of the apparatus 45 is illustrated in FIGURE 9 and comprises rigid metallic member 55 comparable to member 5I but having the outer peripheral surface thereof covered by a resilient layer 56 which is relatively soft and relatively thin.

For example, the layer 56 can compries rubber in the order of 1/32 of an inch thick and having a durometer rating of approximately 35 to 45.

The rolls 46 and 47 of the apparatus 45 of this invention are so constructed and arranged that the same act on the strip of material 48 in the manner illustrated in FIGURE 10.

While the strip of material 4S can comprise any suitable material, the embodiment thereof illustrated in the drawings is approximately 0.003 to 0.005 of an inch thick and comprises an outer strip of metallic foil 57, such as aluminum-containing metallic foil or the like, laminated to a strip of paper backing material 58 by an intermediate adhesive layer 59.

As the strip of material 48 is continuously fed through the nip of the cooperating rolls 46 and 47 from left to right in the manner illustrated in FIGURE while the roll 46 is rotating in a counterclockwi-se direction and the roll 47 is rotating in a clockwise direction, the strip of material 48 is so compressed between the rolls 46 and 47 that the outer peripheral surface 53 of the embossing roll 46 pushes the strip of material 48 into the resilient layer 56 of the backup roller 47 to such a degree that the resilient layer 56 of the backup roll 55 tends to ow into thecavities 54 of the embossing roll 46 in much the same manner that the wax-like layer 38 of the structure illustrated in FIGURE y5 tends to tlow into the cavities 35 of the embossing plate 33 whereby the strip of material 48 is forced into the cavities 54 of the embossing roll 46 by the resilient layer 56 of the backup roll 55 without requiring an intermediate wax layer to flow in the manner provided by the prior known sheet fed apparatus of FIGURES 4 and 5.

Thus, it can be seen that the sheet of material 48 can be rapidly moved through the nip of the cooperating rolls 46 and 47 without requiring the strip of material 48 to have the intermediate wax layer thereof iiow in the manner required by the apparatus illustrated in FIG- URES 4 and 5 so` that the embossing operation on the sheet of material 48 by the apparatus 45 of this invention can be at a relatively fast rate compared to the prior known texture embossing method and apparatus.

While thecavities 54 formed in the copper layer 52 of the embossing roll 46 of the apparatus 45 of this invention 'can have any desired depth, it has been found that the minimum depth of each cavity 54 should be between 1/2 to 3%: of the cavity itself to permit high speed operation and to enable the lines to be seen.

Therefore, by merely etching the embossing roll 46 of this invention with the desired pattern, the sheet of material 48 can be continuously embossed with a repeating pattern to produce the desired effects previously described. While the degree of contrast depends upon the number of hill and valley angles employed and the 'skill of the designer, one typical example of a successful textured embossed container wrap contained hills and valleys running at six different angles, such as is illustrated in FIGURE 3. However, for many packages, the desired effect could be achieved with much less, often merely by contrasting two elements by embossing one with vertical hills and valleys and the other with horizontal hills and Valleys.

Further, because the strip of material 48 being textured embossed by the apparatus method 45 of this invention is subesquently wound into the roll 50, such textured embossed material readily lends itself to high speed mass production packaging machinery or the like which cannot accept single sheets of material in the manner produced by the prior art embossing apparatus of FIGURES 4 and 5.

Further, lower costs result from the use of the rubbercoated backup roll 47 of this invention rather than the backup cylinder 41 of the registering embossing .apparatus illustrated in 39 because no etching is necessary on the rubber backup roll 47 of this invention whereby close tolerances need not be maintained between the rolls 46 and 47.

Thus, it can be seen that it is relatively economical to initially form the embossing and backup rolls of this invention and that the apparatus can be economically run at a high speed t0 continuously emboss a sheet of material 48 which can be subsequently shipped and stored in roll form not permitted by the prior art.

While the invention has been described for achieving a textured'embossing pattern having atleast 50 lines per inch in order to give sufficient angularity for'reective purposes, this limitation must be considered 4in the light of the thickness of the sheet material used in the order of .003 to .005 of an inch. If a heavier sheet material is used the number of lines required to achieve this angularity may be less and the scope of the appended claims is intended to reflect this consideration. p

Accordingly, it can be seen that this invention provides an improved method and apparatus for continuously texture embossing a sheet of material or the like as well -as improved parts for such an apparatus or the like.

While the form of the invention now preferred has been disclosed as required by` the statutes, other forms may be used, all coming within the scope of the claims which follow.

What is claimed is:

.1. A method for continuously embossing a sheet of material with a textured embossing pattern having at least 50 lines per inch, said sheet being approximately 0.003 to 0.005 of an inch thick and comprising a metallic fo-il layer laminated to a paper backing layer by an intermediate adhesive layer, said method comprising the step of continuously passing said sheet of material through a nip of a pair of cooperating rolls, one roll having a pattern of valleys and hills in the outer periphery thereof and the other roll having resilient means to push said sheet into said valleys as said sheet passes through said nip and is textured embossed thereby, said resilient means of said second roll comprising a layer of rubber having a. durometer rating of approximately 35 to 45 and a thickness of `approximately 1/32 of an inch.

2. A method for continuously embossing a sheet of material with a textured embossing pattern having 50 lines more or less per inch, said sheet being approximately 0.003 to 0.005 of an inch thick and `comprising a metallic -foil layer laminated to a paper backing layer by an intermediate adhesive layer, said method comprising the step of continuously moving said sheet of material through the nip of a pair of cooperating rolls, one of said rolls being provided with the desired embossing pattern in the form of hills and valleys on the outer periphery thereof and the other roll having a relatively hard backing material covered with .a relatively thin layer of relatively soft material whereby said covering on said other roll pushessaid sheet into said valleys of said one roll as said sheet continuously passes through the nip of said rolls and is textured embossed thereby said relatively thin layer of relatively soft material comp-rising a layer of rubber having a durometer rating of approximately 35 to 45 and a thickness of approximately 1/2 of an inch.

3. Apparatus for continuously embossing a sheet of material with a textured embossing pattern having at least 50 lines per inch, said sheet being approximately 0.003 to 0.005 of an inch thick and comprising a metallic foil layer laminated to a paper backing layer by an intermediate adhesive la-yer, said apparatus comprising a iirst roll having a pattern of valleys and hills in the outer periphery thereof, a second roll cooperating with said iirst roil to dene a'nip therebetween, and means for continuously moving said sheet through said nip, said second roll having resilient means to push said sheet into said valleys of said iirst roll as said sheet passes through said nip whereby said sheet is continuously textured embossed by said rolls, said resilient means of said second roll comprising a layer of rubber having a durometer rating of approximately 35 to 45 and a thickness of approximately 1/32 of an inch.

4. Apparatus for contin-uously embossing a sheet of material with a textured embossing pattern having at least 50 lines per inch, said sheet being approximately 0.003 to 0.005 of an inch thick and comprising a metallic foil layer laminated to a paper backing layer by an intermediate adhesive layer, said apparatus comprising a first roll having a pattern of valleys and hills in the outer periphery thereof, said pattern including a plurality of sets of substantially straight and parallel valleys and hills, each set being disposed angularly relative to the .other sets, a second roll cooperating with said first roll to define a nip there* between, `and means for continuously moving said sheet through said nip, said second roll having resilient means to push said sheet into said valleys of said first roll as said sheet passes through said nip whereby said sheet is continuously textured embossed by said rolls, said resilient; means of said second roll comprising a layer of rubber having a durometer rating of approximately 35 to 45 and a thickness of approximately 1/32 of an inch.

5. Apparatus as set forth in claim 4 wherein there are a plurality of like sets of valleys and h-ills in said outer periphery of said first roll.

6. Apparatus for continuously embossing a sheet of material with a textured embossing pattern having 5 0 lines more or less per inch, said sheet being approximately 0.003 to 0.005 of an inch thick and compr-ising a metallic foil layer laminated to a paper backing layer by an intermediate adhesive layer, said apparatus comprising a first roll having a pattern of valleys and hills in the outer periphery thereof, a second roll having a relatively hard back-ing vmaterial covered with a relatively thin layer of relatively soft material, said thin layer of relatively soft material comprising a layer of rubber having a durometer rating of approximately 35 to 45 and a thickness of approximately 1/32 of an inch, `and means for continuously passing said sheet through the nip of said rolls whereby said covering of said second roll pushes said sheet into said valley of said first roll as said sheet continuously passes through said nip and is textured embossed thereby.

7. Apparatus as set forth in claim 6 wherein the maximum depth of a valley is approximately 1/2 to 3A of the width of the valley.

8. Apparatus for continuously embossing a sheet of material with a textured embossing pattern having 50 lines more or less per inch, said sheet being approximately 0.003 to 0.005 of an inch thick and comprising a metallic foil layer laminated to a paper backing layer by an intermediate adhesive layer, said apparatus comprising -a first roll having a pattern of valleys and hills in the outer periphery thereof, said pattern including a plurality of sets of substantially straight and parallel valleys and hills, each set being disposed angularly relative to the other sets, a second roll with a relatively hard backing material covered with a relatively thin layer of relatively soft material, said relatively th-in layer of relatively soft material comprising a layer of rubber having a durometer rating of approximately 35 to 40 and a thickness of approximately lg of an inch, and means for continuously passing said sheet through the nip of said rolls whereby said covering of said second roll pushes said sheet into said valleys of said first roll as said sheet continuously passes through said nip and is textured embossed thereby.

9. Apparatus as set forth in claim 8 wherein there are at least two different sets of valleys and hills in said first roll.

l0. Apparatus as set forth in claim 8 wherein the outer periphery of said first roll is copper-containing material.

11. Apparatus as set forth in claim 8 wherein said backing material of said second roll is ferrous-containing material.

References Cited by the Examiner UNITED STATES PATENTS 295,986 4/1884 Crooke 101-23 331,769 12/1885 Compton 101--23 366,755 7/1887 Baker 101-23 482,267 9/1892 NeWOn lOl-23 1,455,172 5/1923 Prudhomme 101-23 2,080,276 5/1937 .lenett lOl-32 2,593,149 4/1952 Illner lOl-23 2,893,320 7/ 1959 Jones 101--426 3,008,257 11/1961 Landgraf lOl-32 ROBERT E. PULFREY, Primary Examiner.

WILLIAM B. PENN, Examiner. 

1. A METHOD FOR CONTINUOUSLY EMBOSSING A SHEET OF MATERIAL WITH A TEXTURED EMBOSSING PATTERN HAVING AT LEAST 50 LINES PER INCH, SAID SHEET BEING APPROXIMATELY 0.003 TO 0.005 OF AN INCH THICK AND COMPRISING A METALLIC FOIL LAYER LAMINATED TO A PAPER BACKING LAYER BY AN INTERMEDIATE ADHESIVE LAYER, SAID METHOD COMPRISING THE STEP OF CONTINUOUSLY PASSING SAID SHEET OF MATERIAL THROUGH A NIP OF A PAIR OF COOPERATING ROLLS, ONE ROLL HAVING A PATTERN OF VALLEYS AND HILLS IN THE OUTER PERIPHERY THEREOF AND THE OTHER ROLL HAVING RESILIENT MEANS TO PUSH SAID SHEET INTO SAID VALLEYS AS SAID SHEET PASSES THROUGH SAID NIP AND IS TEXTURED EMBOSSED THEREBY, SAID RESILIENT MEANS OF SAID SECOND ROLL COMPRISING A LAYER OF RUBBER HAVING A DUROMETER RATING OF APPROXIMATELY 35 TO 45 AND A THICKNESS OF APPROXIMATELY 1/32 OF AN INCH. 